Thermoplastic starch

ABSTRACT

Described is a method for producing a thermoplastic starch, wherein a mixture is extruded comprising starch and a polyol, preferably selected from the group comprising polyethylene glycol, monosaccharides, sugar alcohols and mixtures thereof, in a quantity of 0 to 9.9 wt. % of the mixture, and an epoxide, selected from the group comprising epoxidised vegetable oils, and mixtures thereof, in a quantity of 0.1 to 6 wt. % of the mixture, the mixture further containing an acid, preferably a carboxylic acid selected from the group consisting of citric acid, malic acid or tartaric acid, in a quantity of 0.1 to 1 wt. % of the mixture, and being devoid of polyester urethane. The invention also describes a thermoplastic starch produced in this way, a compound produced with the aid of the thermoplastic starch, and a film produced from such a compound or an injection-moulded item produced from such a compound.

The present invention relates to a method for producing thermoplastic starch, a thermoplastic starch produced in this way, a compound containing the thermoplastic starch, and a film produced from such a compound.

According to the definition of Carvalho, thermoplastic starch (hereinafter also referred to as TPS) is an amorphous or semi-crystalline material consisting of broken-down or destructured starch and one or more plasticisers. TPS may be repeatedly converted into the plastic state and re-hardened, enabling it to be shaped under the action of heat and shear stress, which allows it to be processed using plastics industry techniques. TPS as a material usually has a hydrophilic character, which means that the material properties are strongly dependent on the climatic environmental conditions. For this reason, TPS is rarely used directly or solely for producing bioplastics. The use of finely distributed TPS (disperse phase) in a polymer matrix (continuous phase), on the other hand, offers the possibility of a) considerably increasing the bio-based portion in plastics formulations and b) integrating a biodegradable component, depending on the choice of matrix polymer. Materials which are required to be completely biodegradable or compostable (for example according to standard EN 13432) require the use of a polymer matrix which may be decomposed in a biological medium and under the action of water by the influence of microorganisms.

Thermoplastic polymers may be melted repeatedly by increasing the temperature. After cooling, they are present in a predominantly crystalline or amorphous structure. This property is used for the purpose of shaping and functions due to the fact that the glass transition temperature (Tg) of thermoplastics is below room temperature. Native starch does not demonstrate this behaviour. When processed into a thermoplastic material, the originally semi-crystalline, granular structure is broken up to create a continuous amorphous phase, thus making starch accessible for shaping by conventional plastics processing methods. When heated above the gelatinisation temperature, starch begins to swell in the presence of water. During this process, liquid diffuses into the interior of the grains and ultimately interacts with the free hydroxy groups of the starch molecules. This breaks the hydrogen bonds, the material loses crystallinity, and lastly amorphous areas start to dissolve. The process is fundamentally determined by the temperature curve. Up to a threshold value of approximately 50° C. the procedure is reversible. Further heating causes irreversibly strong swelling. The loss of crystallinity causes the starch grains to lose their onion-skin structure and the birefringence visible under microscope, and the viscosity of the suspension increases rapidly. In an extrusion process, plasticisers are also added in addition to water to achieve the breakdown of the starch under these water-limited conditions. By using plasticisers such as glycerol, sorbitol, erythritol, polyethylene glycol, various mono- and disaccharides or sugar alcohols, intermolecular interactions are reduced, similarly to the effect of water, by breaking the hydrogen bonds between the starch molecules. The procedure in the extruder is accompanied by a splitting of the polymer chains and thus a partial depolymerisation, which causes both the melting and the glass transition temperature to drop below the degradation temperature (230° C.).

U.S. Pat. No. 5,362,777 discloses the production of thermoplastic starch (TPS) with the addition of plasticisers, for example sorbitol; plant fats may also be added to improve the flow properties.

WO 99/61524 relates to a film made from a thermoplastic polymer mixture containing TPS, at least one polyester urethane, a plasticiser such as sorbitol and oils containing epoxide groups as lubricants, in particular epoxidised linseed oil.

DE 198 24 968 A1 also discloses a film made from a thermoplastic polymer mixture containing TPS with a polymer obtainable by polycondensation or polyaddition, containing plasticisers, for example sorbitol, and plant fats or oils as lubricants.

According to WO 2012/162085 A1, TPS, oil and/or wax (epoxidised plant oil or linseed oil) are disclosed. TPS is a starting product; the presence of another thermoplastic polymer is absolutely necessary for the processing of thermoplastic starch.

Lastly, WO 2006/042364 A1 discloses a mixture of sorbitol and other plasticisers, for example epoxidised linseed oil. Starch is a starting product. Apart from starch, a water-soluble polymer is also present, for example polyvinyl alcohol, polyvinyl acetate or copolymers of ethylene and vinyl alcohol.

The TPS already known from the above-mentioned prior art, despite the addition of plasticisers, is inherently brittle and hydrophilic. Thus, when using pure TPS, the high demands (strength, water resistance) placed on technical products in film extrusion cannot be met. In particular, it is difficult to stand up to a comparison with synthetic polymer systems in terms of processability and end product properties (extensibility, tensile strength). Furthermore, it has been shown that if the approach of compound production based on glycerol-plasticised, non-reactively functionalised TPS is followed, fundamental problems arise during the course of technical implementation.

Due to large differences in viscosity, a fine dispersion of TPS in a polymer matrix is only efficient under high shear (the TPS has a very high viscosity, whereas the polymer tends to have a low viscosity). This may lead to mechanical damage of the TPS phase and an associated brown colouring of the compound material. In addition, the high viscosity of the untreated TPS makes processing more difficult, which is reflected in increased torque and pressure conditions in the extruder.

In addition, the compatibility at the interfaces between the hydrophilic TPS and the hydrophobic polymer is limited, which leads to an impairment of the mechanical material properties (tensile strength, extensibility) in the end product.

Furthermore, in both flat and blown film processing, smoke or glycerine vapours are generated from a processing temperature of approximately 150° C. Depending on the TPS content added, the temperature must generally be raised to at least 150° C. to give the TPS polymer melt an appropriate flowability. This leads to a loss of plasticiser in the material (and thus to a deterioration in quality), as well as to the undesired formation of condensate on the plant cooling units.

Due to the water bound in the starch, there is also a process-dependent, more or less strong expansion of the polymer melt at the die outlet (formation of bubbles on the surface due to the escape of water vapour). The exclusive substitution of glycerol by plasticisers (polyols) of higher molar mass, such as sorbitol, isosorbide or xylitol in the TPS has been proven to lead to a deterioration of the achievable mechanical properties (extensibility and/or tensile strength, tear resistance) in the case of film materials based on TPS and polymer.

Due to a lack of compatibility, the TPS qualities currently available on the market do not usually allow for use in a proportion of over 30-40 wt. % in the compound or film, without the mechanical properties of the end products (films) suffering greatly. However, it would be desirable to produce films with the highest possible proportion of renewable raw materials such as TPS.

DE 198 22 979 A1 discloses films produced by extruding a mixture containing thermoplastic starch and/or a thermoplastic starch derivative, at least one polyester urethane, glycerol and epoxidised linseed oil. Acids are mentioned in a combination of TPS with a polyurethane as crosslinking agent.

WO 2012/162092 A1 discloses the production of thermoplastic starch by extruding a mixture containing starch, polyol and epoxidised plant oil.

CN 108 192 302 A describes a biodegradable material comprising a material B, which material B in turn contains a starch Master Batch for example of 70% starch, 3% coupling agent, 2% paraffin, 22.9% glycerol, 0.1% citric acid, and 2% epoxidised soybean oil. The amount of glycerol varies, depending on the example in this document, between 22.9 and 30%.

The object of the present invention is to overcome the above-mentioned disadvantages of the prior art and to provide a TPS which is free from polyester urethane and which is suitable for producing compounds with at least one thermoplastic polymer which may be used as a compound for producing films by means of blown film or flat film extrusion.

This object is achieved in accordance with the invention by a method for producing thermoplastic starch, in which method a mixture comprising starch and a polyol, preferably selected from the group comprising polyethylene glycol, mono- and disaccharides, sugar alcohols such as glycerol, sorbitol, erythritol, xylitol or mannitol and mixtures thereof, in a quantity of from 0 to 9.9 wt. % of the mixture, and an epoxide selected from the group comprising epoxidised plant oils such as soybean oil, linseed oil, sunflower oil, rapeseed oil and mixtures thereof, in a quantity of from 0.1 to 6, preferably 1 to 4.5, particularly preferably 2 to 3.5 wt. % of the mixture, is extruded, wherein the mixture also contains an acid, preferably a carboxylic acid selected from the group consisting of citric acid, malic acid or tartaric acid, in a quantity of from 0.1 to 1, preferably 0.1 to 0.5 wt. % of the mixture and is free from polyester urethane. The invention is a formulation for producing thermoplastic starch (TPS) with an optimised property profile from the point of view of both processing and material properties. The starting materials used are starch, a plasticiser (0-9.9 wt. %), an acid (0.1-1 wt. %) and an epoxidised plant oil (0.1-6.0 wt. %). The end product is cold water swelling to cold water soluble. For producing thin-walled film materials (in the range of, for example, 10-50 μm thickness) it is important to distribute the TPS as finely as possible in the compound matrix. The acid used for the extrusion of starch together with the optionally present polyol and an epoxide acts both as an activation agent for the epoxide and as a processing aid, since it a) caps the branch chains on amylopectin and thus increases the proportion of linear molecules. The behaviour of the polymer is thus similar to that of conventional thermoplastic materials. b) Furthermore, during the course of the acid addition, a depolymerisation of the molecules at the glycosidic bond occurs. The effect of a change to process conditions, such as temperature, pressure and dwell times, can thus be better estimated. For this purpose, for example, carboxylic acids such as citric acid, malic acid, acetic acid or tartaric acid have proven to be of use. With regard to the stated quantities, it must be stated that ranges below 0.1 wt % are difficult to realise in practice, and above approximately 1 wt. % there is (depending on the acid used) a drastic reduction in the molecular mass and thus associated quality losses, a strong foaming of the melt, whereby granulation is no longer possible, and a strong formation of dust on account of TPS abrasion. Surprisingly, it has also been found that a TPS particle size of <5 μm in the polymer matrix may be achieved with the thermoplastic starch produced in accordance with the invention in order to avoid the formation of micro-roughness (film surface) and the occurrence of associated mechanical weak points. The use of this TPS in the form of a finely distributed disperse compound phase in combination with, for example, degradable thermoplastic polyesters (the continuous phase) offers a simple possibility to increase the moisture resistance and to optimise the final product properties. In this way, the biodegradability of the end product may also be adjusted. The sustainable character of the end product may be increased by the elevated content of TPS which is made possible as a result. For the epoxide, it has been found that the absorption capacity of the melt is exhausted at 6.0 wt. %; a higher addition leads to oily deposits on the product and/or equipment.

The amount of starch in the mixture used in accordance with the invention to produce thermoplastic starch is preferably the missing remainder to 100 wt. % of the mixture, required in addition the other ingredients present (polyol, epoxy and acid), however, other auxiliaries and additives known to a person skilled in the art may also be present as necessary. In any case, the mixture used in accordance with the invention to produce thermoplastic starch is free from polyester urethane(s).

FIG. 1: TPS as a) blind sample (0% ESBO, 0% PBAT) and processed with additional of b) 30% water (2% ESBO, 10% PBAT), c) 40% water (2% ESBO, 10% PBAT).

FIG. 2: Microscopy 100× magnified for analysis of the starch breakdown in the TPS types from FIG. 1.

FIG. 3: Incorporation of the TPS variants from Table 3 herein (rising starch content).

Starch:

The starch used in accordance with the invention may be any conventional tuber, cereal or legume starch, for example pea starch, maize starch incl. waxy maize starch, potato starch incl. waxy potato starch, amaranth starch, rice starch incl. waxy rice starch, wheat starch incl. waxy wheat starch, barley starch incl. waxy barley starch, tapioca starch incl. waxy tapioca starch, and sago starch. Starches of natural origin generally have an amylose content of 20 to 30 wt. %, depending on the plant species from which they are obtained. According to the invention, starches rich in amylopectin, which have a significantly increased amylopectin content, or products containing an increased amylose content, also belong to this category. In addition to the natural starch types rich in amylopectin and high amylose types obtained by breeding measures, also starches rich in amylopectin or high amylose starches obtained by chemical and/or physical fractionation or produced by genetically modified plants may be used. Functionalised starches may also be used and are defined as follows:

Functionalised Starch:

The starch used in accordance with the invention may also be a functionalised starch; if the term “starch” is used in the present description and in the claims, it is also understood to mean a functionalised starch, For example, etherifications or esterifications also fall under the scope of functionalisation. In the following, some derivatisations are described which, alone or in combination with each other, may be provided for further derivatisation of starch derivatives. The type of derivatisation and the raw material basis of the starch used are very closely related to the specific field of application of the particular product. The methods for this are known per se. in particular, the focus here will be on the functionalisation in slurry, paste, (semi-)dry method and functionalisation by means of reactive extrusion.

In general, starch derivatives are divided into starch ethers and starch esters. Furthermore, it is possible to differentiate between non-ionic, anionic, cationic and amphoteric as well as hydrophobic starch derivatives, which may be produced by slurry, paste, semi-dry or dry derivatisation as well as by derivatisation in organic solvents.

Anionic and non-ionic functionalisation of starch includes those derivatives in which the free hydroxyl groups of starch are substituted by anionic or non-ionic groups, Starch may also be anionically functionalised by oxidative processes such as the treatment of starch with hydrogen peroxide or hypolye or by a iaccase/mediator system.

In principle, anionic and non-ionic derivatisation may be carried out in two ways:

a) Functionalisation achieves an esterification of starch. Inorganic or organic acids or salts thereof or esters thereof or anhydrides thereof are used as functionalising agents. Mixed esters or anhydrides may also be used. In the esterification of starch, this may also take place several times, so that, for example, distarch phosphoric acid esters may be produced. Preferably, the starch used in accordance with the invention is the result of an esterification with mono-, di- or tricarboxylic acids with an alkyl chain with 1 to 30 carbon atoms or a carbamate, particularly preferably an acylated, such as a succinylated, octenylsuccinylated, dodecylsuccinylated or acetylated carbamate.

b) During the course of functionalisation, the starch is etherified. Methyl, ethyl, hydroxyethyl, hydroxypropyl, hydroxybutyl, carboxymethyl, cyanoethyl, carbamoylethyl ether starch or mixtures thereof may be used. Cationic functionalisation of starches includes those derivatives in which a positive charge is introduced into the starch by substitution. The cationisation processes are carried out with amino, imino, ammonium, sulfonium or phosphonium groups. Such cationic derivatives preferably contain nitrogen-containing groups, in particular primary, secondary, tertiary and quaternary amines or sulfonium and phosphonium groups which are bound via ether or ester bonds.

Amphoteric starches represent another group. These contain both anionic and cationic groups, making their applications very specific. They are mostly cationic starches which are additionally functionalised either by phosphate groups or by xanthates.

Among the esters, a distinction is made between simple starch esters and mixed starch esters, the substituent(s) of the ester possibly being different: in the ester group RCOO—, the R group may be an alkyl, aryl, alkenyl, alkaryl or aralkyl group with 1 to 20 carbon atoms, preferably 1 to 17 carbon atoms, preferably with 1 to 6 carbon atoms. These products include the derivatives acetate (prepared from vinyl acetate or acetic anhydride), propionate, butyrate, stearate, phthalate, succinate, oleate, maleate, fumarate and benzoate.

Etherifications are largely carried out by reaction with alkylene oxides (hydroxyalkylation) containing 1 to 20 carbon atoms, preferably 2 to 6 carbon atoms, in particular 2 to 4 carbon atoms, in particular by using ethylene oxide and propylene oxide. However, methyl, carboxymethyl, cyanoethyl and carbamoyl ethers may also be prepared and used. An example of carboxyalkylation is the reaction of starch with monochloroacetic acid or its salts. Furthermore, hydrophobic etherification reagents, such as glycidyl ether or epoxides, should be mentioned in particular. The alkyl chain length of the reagents mentioned is between 1-20 carbon atoms, and in addition aromatic glycidyl ethers are also possible.

Examples of derivatisation with glycidyl ethers are o-cresol glycidyl ethers, polypropylene diglycol glycidyl ethers, tert-butylphenyl glycidyl ethers, ethylhexyl glycidyl ethers, hexanediol glycidyl ethers and neodecanic acid glycidyl esters.

Another possibility of alkylation is alkylation via alkyl halides, for example via methyl chloride, dialkyl carbonates, for example dimethyl carbonate (DMC) or dialkyl sulfate, for example dimethyl sulfate.

The starches used for esterification, etherification and cross-linking, and also the chemically non-functionalised starches, may also be tempered (in slurry) or inhibited (dry or semi-dry reaction) by means of thermal-physical modifications.

Starches may also be functionalised by hydrophobing reagents. Etherified hydrophobic starches are obtained if the hydrophobic reagents contain a halide, an epoxide, a glycidyl, a halohydrin, a carboxylic acid or a quaternary ammonium group as functional group. For esterified hydrophobic starches, the hydrophobic reagent usually contains an anhydride. A hydrophobing of the starch may also be achieved by mixing a starch or a starch derivative with fatty acid ester.

All of the mentioned functionalisations of starch may not only be achieved by reacting native starch, but also by using degraded forms. The degradation processes may be hydrolytic (acid-catalysed), oxidative, mechanical, thermal, thermochemical or enzymatic. In this way, the starch may not only be structurally changed, but the starch products may also be made soluble or swellable in cold water.

Lastly, the starch may also be present as a graft polymer or graft copolymer, for example with products from the group of polyvinyl alcohols or polyesters.

Epoxidised plant oils:

From a chemical point of view, the epoxides used in accordance with the invention are cyclic ethers. Epoxides may form interactions with the hydroxy groups of starch. Epoxides also include, inter alia, the epoxidised oils, in particular plant oils, which are used in accordance with the invention. Due to their chemical structure, epoxides are unstable, i.e. the ring structure is opened and may react with the starch or, in combination for example with water, react to form a diol. The opening of the epoxide ring may be catalysed by acids (for example carboxylic acids). Preferably, epoxidised plant oils such as soybean or linseed oil (ESBO, ELO) are used in accordance with the invention. Epoxidised linseed oil has a viscosity of approximately 900 mPas at 25° C. and an epoxide oxygen content of at least 8.5 wt. %. Epoxidised soybean oil, on the other hand, has a viscosity of approximately 300-450 mPas (also at 25° C.) and an epoxide oxygen content of 6.5-7.5 wt. %, The viscosity measurements carried out for the purpose of the present invention were each carried out in a viscometer according to EN ISO 3219.

Polyols:

According to the invention, the mixture contains a polyol selected from the group consisting of sorbitol, erythritol, xylitol, mannitol and mixtures thereof, in a quantity of 0 to 9.9 wt. % of the mixture. In other words, this means that, in accordance with the invention, a plasticiser does not necessarily have to be present, however, should a polyol selected from the group consisting of sorbitol, erythritol, xylitol, mannitol and mixtures thereof be present, it should only be present in a quantity up to at most 9.9 wt. % of the mixture. The polyols are so efficient in the TPS as plasticisers (interaction with hydroxy groups) that processing may take place in the process window (low pressure, low torque). The polyols may also be added to the TPS as a syrup (solution in water), which facilitates the mixing into the melt, resulting in a more homogeneous TPS or even more homogeneous compounds and smooth films. Furthermore, these polyols have the advantage over glycerol that they are solid at room temperature, but are present as a melt during processing and may therefore have a plasticising effect.

Preferably, the mixture as a polyol contains sorbitol or erythritol in a quantity of from 0 to 7 or 2 to 7 wt. %.

It is also favourable if the mixture contains the polyol in a quantity of from 0 to 6 or 3 to 6 wt. %. It has been found that the proportion of polyol as plasticiser in the TPS should not be too high, otherwise potential problems in food contact may occur. The plasticiser could, for example, leak out if it is present in excess, but on the other hand a certain percentage of plasticiser must be present in order a) to be able to process in the process window (pressure, torque) and b) ultimately to achieve the required film properties (extensibility, tensile strength).

According to a further preferred embodiment of the present invention, it is provided that the mixture contains epoxide to polyol in a ratio of 1:1 to 1:4, preferably 1:1 to 1:3, particularly preferably 1:3. In the range of 1:1 to 1:4, TPS processing is good (pressure, torque and cuttability of the melt for producing granules) and an increase in the bulk density is noticeable. A ratio of 1:3 ultimately fulfils all the required properties on the film, namely a tensile strength>10 MPa and an extensibility>300%.

Furthermore, it is favourable if the mixture additionally contains lactic acid in a quantity of 2 to 9, preferably to 7, particularly preferably 3.5 to 4.5 wt. % of the mixture. Lactic acid favours the processability of the TPS (pressure, torque); on the other hand, due to its properties, the acid does not lead to a significant degradation of the starch, and therefore its properties are preserved. In addition, the melt is still cuttable in the concentration range mentioned.

In the method according to the invention, it is preferably provided that the mixture is extruded at a temperature of 100-115° C., preferably in a twin screw extruder and at reduced pressure in the last portion of the extruder. In the specified temperature range, the raw material is thermally stable during continuous processing, and the twin-screw extruder enables efficient destructuring of the starch (breaking up of the crystallinity of the native starch) by forced conveyance. A reduced pressure in the last portion of the extruder is important for adjusting the water content of the TPS product; this affects the processability and should be between 3-7 wt % if possible.

The present invention also relates to a thermoplastic starch obtainable by one of the methods disclosed above, which thermoplastic starch preferably has a bulk density of 70 to 90 g/100 ml. Thus, the thermoplastic starch produced in accordance with the invention is considerably denser than a TPS produced without the use according to the invention of an epoxide, for which purpose reference is also made to the attached FIG. 1, in which these differences are clearly visible. Determined bulk densities of thermoplastic starches produced in accordance with the invention are also shown in Table 1.

TABLE 1 Comparison of bulk densities Bulk density (loose) 1^(st) bulk 2^(nd) bulk 3^(rd) bulk Mean density density density value [g/ [g/ [g/ [g/ Concentration 100 mL] 100 mL] 100 mL] 100 mL] Blind sample 0 28.77 27.98 27.62 28.12 (0% ESBO, 0% PBAT) 30% water 1 85.77 85.03 86.51 85.77 (2% ESBO, 10% PBAT) 40% water 2 80.63 78.71 80.28 79.87 (2% ESBO, 10% PBAT)

Also provided for in accordance with the invention is a compound containing such a thermoplastic starch produced in accordance with the invention and extruded with at least one thermoplastic polymer. This enables an increase in the bio-based and biodegradable proportion, as well as the adjustment of the compound ductility by the TPS proportion. Compounds of this type may be used directly for further processing, for example in the film line.

Preferably, such a compound contains as thermoplastic polymer a polymer selected from the group comprising polyolefins, polyamides, polyurethanes, polyesters and mixtures thereof. Preferably, such a compound contains, as thermoplastic polymer, polyesters which are readily miscible with the TPS due to their viscosities. The adjustment of the compound properties, for example the strength, is possible via the polymer blend; surprisingly, with the thermoplastic starch produced in accordance with the invention, it is possible to provide a TPS content in the compound of up to 55 wt. %.

In accordance with a preferred embodiment of the present invention, the above-mentioned compound is produced in a one-step process, wherein a mixture as disclosed previously here for the production of the thermoplastic starch according to the invention is extruded with at least one thermoplastic polymer likewise as disclosed above) at a temperature of 100-175° C., preferably in a twin-screw extruder with separate vacuum zone in which the degassing by application of vacuum occurs.

As already mentioned, the TPS produced in accordance with the invention or a compound containing such a TPS is particularly suitable for producing a film by blown film or flat film extrusion. Surprisingly, it has been found that, during the production of such a film, the practically unavoidable smoking no longer occurs when using a TPS known from the prior art.

Similarly, the TPS produced in accordance with the invention or a compound containing such a TPS can be used particularly preferably for the production of injection moulded articles. The present invention therefore also comprises a use of this kind and an injection moulded article produced using a TPS produced in accordance with the invention or using a compound containing such a TPS.

The above-mentioned mixtures with their individual components are processed into a thermoplastic melt in the extruder under temperature and shear action. The present invention will now be explained in greater detail by means of the following examples:

Corn starch (native corn starch, Maisita 21000) is fed into the extruder as the starting raw material by means of solids metering. Sorbitol is used as the plasticiser component or, if no plasticiser is used, the required amount of water is fed. The plasticiser can be presented here both in solid and in liquid form (solution in water); it is also possible to split the addition (i.e. addition partly in solid and partly in liquid form). Stearic acid (1 wt %) is used to improve processability (torque reduction). Acid and epoxidised plant oils include citric acid (0.1 wt. %) and epoxidised oil (2 wt %). The oil component is added untreated in liquid/pumpable form. In addition, 10 wt. % of the polyester polybutylene adipate-co-terephthalate (PBAT) is added. The mixture is processed using a temperature profile in the range 100-160° C. (from 160° C. a strong brown colouration can be seen) and at a speed of 250 rpm in a twin-screw extruder with vacuum degassing (removal of the water added for the plasticisation) and pelletised at the die plate by means of hot die-face pelletising. All additives are added directly to the extrusion process via corresponding metering apparatuses.

Only the addition of epoxidised plant oils (for example epoxidised linseed oil (ELO), epoxidised sunflower oil, epoxidised rapeseed oil or epoxidised soybean oil (ESBO) and mixtures thereof), as provided for in accordance with the invention, leads to the incorporation/mixing of the plasticiser in the TPS, even when sorbitol is used for example. An improvement of the phase compatibility in the compound, through the integration of the oil component in the TPS, subsequently leads to an increase in the mechanical material properties.

The activation of the epoxide functionality in the epoxidised plant oils is promoted by the addition of acids. Preferably carboxylic acids (which ideally may be produced on a sustainable basis) such as citric acid, tartaric acid, acetic acid, itaconic acid, malic acid or lactic acid are used.

Furthermore, the addition of epoxidised plant oil reduces the die pressure and thus inhibits the described expansion (see the attached drawings, from which the advantages of the method according to the invention can be clearly seen).

The addition of process additives to optimise processability is permitted up to a proportion of 3 wt. % (for example fatty acids such as palmitic acid, myristic acid, stearic acid or behenic acid). The starch types, by definition, may be used as starting raw materials, for example with a dry substance of ˜90 wt. %.

The resultant material is water-soluble and can be incorporated as a finely distributed TPS (disperse phase) by means of a separate extrusion step into, for example, polymer melts (continuous phase) (FIG. 3).

The extrudates produced in accordance with the invention are suitable for further processing into compounds (for example in combination with polyesters). Only on the basis of the compounds is it possible to produce end products such as film materials.

Suppliers:

Sorbitol, stearic acid—Brenntag, AT

ESBO—Hobum, AT

Citric acid—Jungbunzlauer, AT

Ecoflex, polybutylene adipate-co-terephthalate (PBAT)—BASF, DE

Machine types:

Extrusion (TPS and Compound): Theysson TSK 30, 28D, 7 zones

Blown film line: OCS BFT400V3

-   -   Water-plasticised TPS in comparison with plasticiser-plasticised         TPS (FIGS. 1 and 2)

TABLE 2 Plasticiser content and water addition in the TPS formulation Plasticiser content Separate water addition Batch no. (sorbitol, wt. % in TPS) during extrusion (%) A 4 40 B 6 40 C 18  — X — 40 Y 9 40 Z 9 —

The thermoplastic starch from Table 2 is compounded together with PBAT as polyester in the respective amounts in a twin-screw extruder and is then processed into films (see properties in Tables 3 and 4).

TABLE 3 Compounds based on TPS and the polyester Ecoflex (PBAT, BASF), wherein the TPS was plasticised by the addition of an excess of water X), in combination with sorbitol A), B), Y) or by means of the plasticiser sorbitol alone C), Z) was plasticised, characteristic material values of film materials based on different TPS variants (Table 1) Dosing (TPS Starch proportion proportion in (wt. % the compound Further in the (wt. % Exten- Tensile tear compound, determined sion strength resistance Batch no. theoretically) analytically) (%) (MPa) (N/mm) D 30 25.0 354.7 11.3 95.5 (based on TPS A) E 35 28.5 326.1 25.0 104.2 (based on TPS B) F 45 30.0 285.2 22.2 116.5 (based on TPS C) G 40 26.1 218.4 11.4 80.4 (based on TPS X) H 40 27.0 295.9 27.9 96.5 (based on TPS Y) I 40 26.2 269.0 15.3 100.0 (based on TPS Z)

It can be seen from Table 3 above that if water is added as plasticisation reagent it is possible to produce a TPS which allows comparably good mechanical material properties in the compound or in the film produced on the basis of the compound relative to those that can also be achieved by the plasticisation with sorbitol. It is clear from the performed tests that even a reduction of the plasticiser content to 0 wt. % is possible.

-   -   Rising starch content (FIG. 3)

TABLE 4 Compounds based on TPS and the polyester Ecoflex (PBAT, BASF), wherein the TPS was plasticised by the addition of an excess of water, characteristic material values of film materials based on TPS variant B (Table 2) Starch proportion in the compound Further Batch no. (wt. % Exten- Tensile tear (all based determined sion strength resistance on TPS B) analytically) (%) (MPa) (N/mm) E 28.5 326.1 25.0 104.2 J 34.0 298.5 24.0 115.0 K 38.3 222.1 18.0 120.0

It can be seen from Table 4 above that if water is added as plasticisation reagent it is possible to produce a TPS which allows comparably good mechanical material properties in the compound or in the film produced on the basis of the compound relative to those that can also be achieved by the plasticisation with sorbitol. The exclusive reduction of plasticisers such as sorbitol, isosorbide, or xylitol in a TPS is therefore not expedient and in the case of film materials based on TPS and polymer has proven to lead to a deterioration in respect of the achievable mechanical material properties.

ANALYSIS METHODS

Checking the Starch Breakdown of the TPS:

If an unground sample is available, it must first be ground as finely as possible using a laboratory mill. It is also important to ensure that samples that have already been ground should not be left to stand for too long, as they will quickly attract moisture and thus falsify the result of the dry substance. The dry substance is then determined. Then, the ground TPS is stirred 5.0 wt. % into dry substance, The demineralised water is placed in the beaker and the sample is carefully sprinkled in while stirring. The total weight (sample+demineralised water) is 200 g.

Shearing parameters: 5 minutes at 1000 rpm with a 4 cm toothed disc stirrer.

For analysis, two drops of the well-slurried sample are now applied to a microscope slide by means of a Pasteur pipette and examined under a transmitted light microscope with and without polarisation filter (FIG. 2).

Incorporation of the TPS into the Polymer Matrix:

Some granules of the compound to be examined are briefly dipped in liquid nitrogen, folded in baking paper and carefully broken into fragments with a hammer. The granule fractions are transferred to a glass beaker, coated with 1 M HCL, and stirred for 3 hours on a magnetic stirrer, Hydrochloric acid is then separated out through a folded filter, and the compounds released from starch are rinsed 2-3 times with demineralised water before drying. The moist compound fractions are scattered onto a petri dish and dried in a drying cabinet at 60° C. for one hour. The dried cryogenic fractions may now be examined by electron microscope (FIG. 3).

Determination of the Mechanical Material Properties:

According to EN ISO 527-11-2, Austrian standard ISO 34-1:2005

Determination of the Bulk Density:

“loose bulk density”, determined by loose filling of a 100 ml measuring cylinder

Specification window: 70-90 g/100 ml

Starch Determination in the Compound or on the Film:

The starch contained in the sample is hydrolysed by means of hydrochloric acid (25% HCl, 60° C., 60 min) and then broken down with a starch-specific enzyme to form glucose (starch UV test, Roche). The resultant extinction difference at 340 nm, which occurs with the reaction from NADP+ to NADPH+H+ is detected photometrically and used to calculate the starch content.

In accordance with a preferred embodiment of the present invention, less than 10 polarisation crosses (preferably no polarisation crosses) are visible in the polarisation microscope for the produced thermoplastic starch with starch breakdown. The grain size of the thermoplastic starch as a dispersion in the compound is preferably <5 μm. A size of <20 μm would also make the compound film-accessible, but is associated with poor haptics; a size of <10 μm also makes the compound film-accessible, however, the product has a micro-roughness.

In accordance with a further preferred embodiment of the present invention, the films produced from a TPS or compound produced in accordance with the invention show an extensibility of >300% with a tensile strength of >10 MPa and superior material properties. 

1.-14. (canceled)
 15. A method for producing thermoplastic starch, comprising extruding a mixture comprising starch and a polyol in a quantity of from 0 to 9.9 wt. % of the mixture, and an epoxidised plant oil in a quantity of from 0.1 to 6 wt. % of the mixture, wherein the mixture also contains an acid in a quantity of from 0.1 to 1 wt. % of the mixture, and is free from polyester urethane.
 16. The method of claim 15, wherein the mixture contains a polyol selected from the group consisting of sorbitol, erythritol, xylitol, mannitol and mixtures thereof, in a quantity of up to 7 wt. %.
 17. The method of claim 15, wherein the mixture contains sorbitol or erythritol in a quantity of up to 6 wt. %.
 18. The method of claim 15, wherein the acid is a carboxylic acid selected from the group consisting of citric acid, malic acid and tartaric acid.
 19. The method of claim 15, wherein the mixture comprises soybean oil, linseed oil, sunflower oil, rapeseed oil and mixtures thereof in a quantity of from 1 to 4.5 wt. % of the mixture.
 20. The method of claim 15, wherein the mixture contains epoxide to polyol in a ratio of 1:1 to 1:4.
 21. The method of claim 20, wherein the mixture contains epoxide to polyol in a ratio of 1:1 to 1:3.
 22. The method of claim 15, wherein the mixture additionally contains lactic acid in a quantity of 2 to 9 wt. % of the mixture.
 23. The method of claim 22, wherein the mixture contains lactic acid in a quantity of 4 to 7 wt. % of the mixture.
 24. The method of claim 15, wherein the mixture is extruded at a temperature of 100-175° C.
 25. A thermoplastic starch obtainable by a method according to claim 15, which has a bulk density of 70 to 90 g/100 ml.
 26. A compound containing a thermoplastic starch according to claim 25 extruded with at least one thermoplastic polymer.
 27. A method for producing a compound according to claim 26, wherein a mixture of claim 15 is extruded with at least one thermoplastic polymer at a temperature of 100-175° C.
 28. A film produced by blown or flat film extrusion according to a compound of claim
 26. 29. An injection moulded article produced by injection moulding a compound according to claims
 26. 